FOSESFEFHFSFHSSFSHFHOSFHSSHSSEBEIESSEY ExonMobil. Development Drilling Operational Practices Top 40 Hit List Drilling Technical Operations SupportVOCSFTTFFIFDIFIIFSFISSIHOSHVwVvswy Drilling Operational Practices Top 40 Hit List Detailed Discussion When the “Top 40 Hit List" was first distributed in 2003, its objective was to establish consistent practices across the global Drilling organization to reduce non-productive time (NPT), enhance performance, improve wellbore quality, and reduce operational risk. The practices in the Top 40 have been proven in one or more Drill Teams and have delivered significant cost and/or operational benefit. As new practices develop, and existing Top 40 practices achieve consistent application, the list is periodically updated. In January 2007, a survey was distributed to the Drill Teams requesting feedback about the implementation and relevance of the existing “Top 40 Hit List.” This feedback was subsequently collected, analyzed, and discussed within the Drilling Technical Team. The Top 40 was enhanced and the upgraded Hit List was provided to the Drill Teams for final ‘comment. As a result, several areas have been revised to reflect recent learnings and successful practices that have been developed in the past ‘couple of years. Fifteen (15) items have been moved to Appendix A, “Oldies but Goodies,” as evergreen practices that should retain focus but do not require special emphasis because they have achieved consistent implementation throughout the Drill Teams. These practices were removed from the active Top 40 but should not be forgotten.Fifteen (15) new items have been added to the list based on suggestions and meetings with the Drill Teams, results Of root cause analysis studies recently performed and Drilling Technical Te-am suggestions. Many of the new Top 40 practices are related to Fast Drill and Hole Cleaning (which are both new categories) replacing Drilling Rate Performance and High Angle Practices, respectively. A new Workflow category has also been introduced. Its intent is twofold: 1) to create a sensitivity to “IHQ near misses’ to prevent NPT, and 2) to use all available real-time data to identify the sources of crilling dysfunction so proper corrective actions are taken. The practices in this category are vital to the success of all other operational practices. The detailed discussions are provided to offer additional explanation of how the practices work, the reasons why they are recommended, and the risks associated with them. In some case$, it is important that special mitigators are implemented along with the change in practice and, therefore, the detailed discussion should be reviewed thoroughly before making the change. The Driling Technical Team is available for additional discussion. The appropriate technical contact for each item is given below and indicated by thelr initials after each Top 40 item. Meee eaeeeeaeaeeane aaeaeeaanete eaFHSSSSSSFFFFFETSIITIIVwsow Table of Contents Technical Contacts.. Revisions / Updates 12 Added items 12 Significantly Updated Detailed Discussions.............. ve Items Moved to "Oldies but Goodies” (See Appendix A)....nnnnnnnnnnennnnae 0 Workflow... 1. Use the digital drilling data to help identify the root cause of NPT events. (WCE) . 2. React to eliminate the causes of “near misses” as “gorousy as we react to eliminate the causes of NPT. (SCZ). Hole Cleanin, 3. Use onsite torque and drag (T&D) monitoring while driling, tripping, and running casingfiners in wells over 40 degrees. (WCE) 29 4. Drop down and MR MC rather than POOH through tight spots with grater han 30 (4 mee tos) overpul nw ve 40 degrees oe: (WCE). 5._ Eliminate backrearing ou except when Foe coins prove the need in wells over 40 degrees. (WCE)... oe 6. When backreaming is required, follow proper IHQ procedures to minimize packoffs and stuck pipe in wells over 40 eres See detailed Top 40 discussions. (WCE).... a 7. Use ToolPro Hole Cleaning software for well planning and for surveillance checks when parameters change. (WCE)... 8. Focus on GPM reading in aton toyed print for hale cleaning (Ble).TRESSTEFETSESEPSSESIESIVsssy 1. Wellbore Stability. 12, z Set casing on bottom or as close to bottom as possible. Minimize the fatal below the casing shoe to help migate hole ecening prbloms (WCE)..... Use mechanical cuttings bed ‘string’ tools to help improve hole cleaning in wells over 40 degrees. These tools wll be beneficial in hole sectors tat are fet to efectvely clean Le big hls, enlarged holes, limited hydraulics, ete.) (WCE)... Do not rely on sweeps to clean your hole. (SCZ)... Every driling program should address wellbore stabiity and include wellbore stability chart on wells or fields with a risk or history of borehole instability. (MJT)... . Collect geomechanics data for all new fields and existing fields with increased well complexity (drawn-down sands, longer reach, and higher angles). (MJT)... . “Slow pump out” during trips or “increase the mud weight” prior to tripping out on wells prone to hole collapse — “swabbing action” during trips may lead to wellbore instability. (WCE). Implement sonic caliper surveillance practices in wellbores that penetrate weak, failure-prone shale. (MJT). . Thoroughly describe material circulated from the wel in each moming report and fake photephs when tere ae inoatone of welbore failure or tight hole. (MJT)... Proactively maintain sufficient mud weight from the start of each interval to prevent hole enlargement. (MJT).. React immediately to signs of instabilty by increasing mud weight and/or inhibition to prevent further hole enlargement. Adjust hole dering and tipping pracons to aocun for known enlargements, (MIT) essebORSTSFVPBDVPVPVVIVISVVVIVIVyVy Narrow Margin Drilling. 419. Prioritize wellbore stabilty over lost retumns when programming mud weight. The consequences of wellbore collapse are greater than the consequences of lost retums. (JT)... 20. Monitor ECD management practices closely on wells with little tolerance between cynamic circulation pressures and Fracture Closure Stte8s (FCS). (SCZ) nnn 21. Develop a detailed mitigation plan for narrow margin dling. SCZ) Lost Returns and FCS Practices. 22. Use the Lost Returrs Mitigation Guide and the estimated permeability to select initial treatment. (FED)... 23. As per Seepage Treatment Guide (no fracture propagation), use only < 25 micron blocking material unless the estimated rock permeability is larger than 2 Darcy. (FED) . 24. Utilize a displacement plot to monitor and document lost returns while running casing in wells with potential losses. (FED) Stuck Pipe Avoidance. 25. Avoid using sleeve stabilizers (andlor other specialty tools and subs) if the bypass area is more limited than your normal BHA components. (WCE)... 26. Manage the driling process (fluids and mechanics) to eliminate differential and mechanical sticking in fiter cakes. Conduct PPA testing in high perm. (FED)... Fast Drill Process 27. Conduct drilkrate tests to determine ROP limits. Modify design, operational practices, or equipment to extend the limits. (FED) 28. Conduct a vibration management study during the early wells in major programs. (FED)...IHUSHSHOHOHOSOVVVPVVVVVVVVUVUYW Conduct RPM whirl tests and monitor the vibration sensor tools to ‘optimize the rotary speed and minimize/eliminate rotation-nduced whirl when rotating off-bottom during MR MC, reaming, backreaming, downreaming, etc., operations. (WCE) . Use minimum 4-in (101.6-mm) length and dimensional relief features in gauge design of RSS bits (ie., undercut, tapered, stepped), regardless of directional company recommendations. (FED)... Apply bit weight quickly while retuming to bottom. Use the lowest RPM that does not allow stick slip (usualy 60 to 80) while applying WOB. (FED). In procedures for all intervals, specify 1) ROP limiter, 2) plan to extend limiter, 3) risk associated with higher ROP, and 4) plan to mitigate high ROP risk. (FED)... When hole cleaning or other factors limit ROP, reduce the aggressiveness of the bit to allow higher WOB to be used to minimize whirl and downhole tool damage. (FED)... Drilling Fluids. 34. Utiize Particle Size Distribution (Ps) to manage solids control and theology. (BLE). 35. Select appropriate blocking particle size(s) utllzing the Particle Plugging Apparatus (PPA) to form an effective filter cake to prevent hole enlargement in unconsolidated sands, seepage losses, and stuck pipe. (BLE)..... : 7 Cementing 29. x 3. 32. 33. 36. Enhance cement squeeze practices: 1) large spacer, 2) high displacement rate, 3) hesitation squeezing. (OCB)... Well Control... 37. Assess whether underground flow is occurring after shutin to determine whether Driller’s Method is appropriate. (JLH)...PODDDODIVDIIDVIOVOVOVDIISIIIVVY 38. Ersure crew proficiency drils are routinely conducted and documented onthe daily drilling report. (JLH). Other 39. Dril and underream (or drill wtile hole opening) at the same time, except for specifically analyzed cases, to better manage vibrations and imorove overall driling performance. Driling and underreaming can also provide significantly increased flow-by area around the BHA components making it easier to trip out of the hole and reducing E ECD. (WCE). Folow te cil best rates for whpatock casing ext design and execution. (TT) ‘Appendix A — “Oldies but Goodies’ {+ Ure MR MG as saad operating procaie while tng and prior to trips. (WCE)... 2. Plan wells such that dril string side loads do not exceed 2000 Ib (907 kg)jjoint. (WCE). 3. Optimize number of bottoms up utiized in mature programs; three to five may not be required. (WCE). 4, Manage swab pressures by optimizing drilling fluid properties such that gel strengths are lat and non-progressive. (SCZ) . 5. Document and plot squeeze pressures during LCM treatments. (FED) 6. Utiize EMDC Integrity Testing Workbook for integrity tests. (FED)... Utiize hydrostatic packers to control displacement when wells will not stand full. (FED)... 8 Execute the “Three Step Response" immediately if the annulus will not stand full after lost returns. (FED)... 9. Nodrill collars above top stab in directional wells. (FED) 418. 19. 24. 2 2. 2 |. Design BHA to achieve Effective Hole Size for planned casing. (FED).. . Avoid extended periods of drill string rotation without circulation in . Evaluate ROP enhancers in wells with WBM < 15 lbigal (1.80 sg). FED) ). Use no more than two drill collars above top stab in straight holes with sticking potential. (FED)... |. Maximum stabilizer spacing of +60 ft (18 m) on wells over 40 degrees cr wells wih differential sticking potential. (WCE)... Centralize casing/liner effectively to reduce the potential for differential sticking. (VICE). Place jars immediately above the likely stuck point; high in BHA of drill collars, low in BHA of HWDP. (FED)... packed-off or partially stuck situations. (WCE)... Treat mud based on mud property trends, not a maintenance schedule based on habit. (MVS) Measure activity with hygrometer on every well drilled with NAF. (MVS) .......0. 116. Utiize Driling Technical Operations Support to install fluids QAIQC processes. (MVS).. sw NT Implement barite sag monitoring on wells over 30 degrees. (BLE)... AAT woe 118 oe 118 Utilize sweep reports to monitor sweep effectiveness. (BLE)... Use GGT to monitor carbonates in WBM, (BLE)... Require the mud engineer to record the Dilution Factor and the average percent driled solids at the end of each interval on the daily mud report. Use this information to determine the efictency of the solids control equipment. (BLE)... Monitor/plot mud properties and product concentrations. (BLE)... Use pipe movement during cementing whenever feasible. (OGB).... Li atox concentration of ges resistant cement 075-80 gps (1.0 gps defaul) (OGB)....FORT FFTIFIIVIOVVOSDHOBSHHVHIVsvse 22. Stnteize on 500 (150) of water wet! space ahead of cement. (OGB) 28. Do not run rigid or solid centralizes in vertical open hole. They do not provide standoff in rugosity. (OG8)..... Ensure service companies are rigged up to record pressures while displacing with either rig pumps or service company pumping equipment. If the rig pump is performing the displacement, this will require the line to the cement unit be left open, or an additional pressure transducer installed in the treating line to allow pressure recording forthe entre displacement period. (OG8).. . 30. Use the new ExxonMobil Well Control Workbook as a iKill Sheet. (LH) Monitor hole with the trip tank anytime circulation is suspended. (FED). a HM. 32. Drilling Supervisor on the rig floor to initiate trips off bottom. (FED) 33. Pump through well control system at frequent intervals. (JLH)... 34, Use Hydril ILLT (Long Life) elements in Hydril GK and GL annular blowout preventers (BOPs). (JLH).. 35. Enhance QA/QC practices atthe rig site, (PCS)... 36. Use integral liner top packers (LTPs). (FED) 37. Follow procedures in the new EMDC Driling Waste Injection Manual when designing and operating waste injection programs. (KRK) . 3 Seek planning input from Driling Technical Operations Support and other Drill Teams, particularly on wells with DCI > 4. (PCS) Appendix B - List of Acronyms...Revisions / Updates ‘Added Items Reason for Catego! Practice Initials my Addition WORKFLOW Use the digital drilling To help identify root (NeW CATEGORY) dala to help identify the | causes of NPT events ry root cause of NPT ovens Eliminate the causes of Emphasize new “near misses” as proactive approach to Po rigorously as we do the | managing NPT. causes of NPT. HOLE CLEANING Set casing on bottom or | Minimize hole cleaning (NEW CATEGORY) as close to bottom as andlor hole instability possible. Minimize the issues associated with WCE rathole below the casing | the exposed casing shoe to help mitigate rathole. hole cleaning problems. Use mechanical cuttings | GlobalShare / Drill bed “stiring® tools to Team learning that Wor help improve hole enhances hole cleaning ‘cleaning. performance. Do not rely on sweeps to | To avoid common SCZ lean your hole. misperception WELLBORE Proactively maintain Minimize hole ‘STABILITY sufficient mud weight enlargement and the from the start of each effects it has on hole MJT interval to preventhole | cleaning and stuck enlargement. pipe.Reason for Category Practice ‘Addition | initials NarROWMARGN — | Develop a Detaled Narrow margin driling Mitigation Plan for was one of the top NPT scz narrow margin drilling. contributors during root cause analysis. ‘STUCK PIPE Manage the driing ‘API high temperature AVOIDANCE process (fuids and high pressure (HTHP) mechanics) to eliminate | tests are run against differential and filer paper that mechanical sticking in| simulates rook with filer cakes. Conduct | 1 md of permeability. fy PPA testing in high PPA testing is required perm, todetermine the required fluid design for actual conditions, particularly in higher permeability. Fast DRILL Conduct RPM whirl tests | Mitigation of whirl PROCESS. ‘and monitor the vibration | vibrations during off- (NEW CATEGORY) sensor tools to optimize | bottom operations the rotary speed and minimizeleliminate rotation-induced whirl when rotating off-bottom WCE during maximum ‘rotation, maximum circulation (MR MC), reaming, backreaming, downreaming, etc., operations. Leeeeeececerceaqqceeeecede.POSTSIFIDIOSHOVOVVOVVVVIVIVFVY Reason for Practice ‘Addition Initials Use the lowest RPM that | Low weight on bit and does not allow stick slip | high RPM when {usually 60-80) while ‘tagging bottom causes FED applying weight on bit whirl, which may cause (WOB), and apply weight | bit and tool damage. quickly In procedures forall Management intervals specify 1) ROP | expectation for all limiter, 2) plan to extend | intervals in all wells. limiter, 3) risk associated | Essential requirement with higher ROP, and, 4) | in Fast Drill Process FED plan to mitigate high (FDP) workfiow to ROP risk. ‘ensure redesign is ‘occurring and risks are managed. When hole clearing or | Control ring wth light other factors limit ROP, ‘WOB results in whirl reduce the that damages the bit ‘aggressiveness of the bit | and tools, Less to allow higher WOB to aggressive bits allow be used to minimize higher WOB to be run FED whirl and downhole tool to mitigate whirl, while damage. ‘maintaining rate of penetration (ROP) below necessary: control drill limits.Reason for Category Practice ‘Addition _| initials DRILLING FLUIDS Select appropriate To provide a tool that blocking particle size(s) | wil help eliminate hole Utlizng the PPA to form | enlargement in an effective filter cake to. | unconsolidated sands, prevent hole ‘seepage losses, and BLE enlargement in stuck pipe. unconsolidated sands, ‘seepage losses, and stuck pipe. WeLL ConTROL Ensure crew proficiency | Crew proficiency is an Aris are routinely expectation in EMC conducted and operations. documented on the daily | Documentation that the dling reports. drils have been JH periodically conducted is essential to stewardship of well control preparedness. OTHER Follow the critical best To collect all best practices for whipstock | practices for whipstock ‘casing exit design and | casing exit design in ‘execution. ‘one location and 7 address common causes of associated NPT. ROBBER OAAAAAAAAAEAAAAEODIBVDDHSOPPVEVIVIVIIIVIVIIITY Significantly Updated Detailed Discussions Reason for Category Practice Up. Initials “HIGH ANGLE Al practices related to hole | Common interest in PRACTICES” cleaning have been hole cleaning a (CHANGED TO regrouped. Practices regardless “HOLE CLEANING” of wel inclination. Eliminate backreaming out | Added comments ‘except when hole conditions | clarifying when Wee prove the need in wells over | backreaming outis a 40 degrees common practice. When backreaming is ‘Added procedural required, folow proper step to do an RPM integrated hole quality (HQ) | whitest to find the procedures to minimize ‘optimum RPM for ackoffs and stuck pipe in| minimizing WCE wells over 40 degrees. See | vibrations. detailed Top 40 discussions. Use ToolPro Hole Cleaning | Added comments software for well planning and | noting that ToolPro surveillance checks. Hole Cleaning software cannowbe | VICE Used for veticaliow angle hole cleaning modeling.Reason for Category Practice Update WELLBORE “Slow pump out” during tips | Modified to include STABILITY or “increase the mud weight” | increasing mud prior to tripping out on wells | weight as an option prone to hole collapse - tomitigate wee “swabbing action” during trips | hydrostatic head may lead to wellbore swab loss when instability. pling out of hole (POOH). “Raise mud weight to manage} Shiting focus to instability rather than raising | alleviating instabiity theologies to clean large first, but debris” updated and ‘emphasizing hole changed to “React cleaning and tripping mediately to signs of practices for instabiity by increasing mud | wellbores with MT ‘weight and/or inhibition to. | known prevent futher hole enlargements. enlargement. Adjust hole cleaning and tipping practices to account for known enlargements.” “Thoroughly describe and Emphasizes need to photograph material describe the material ‘iroulated from the well when | regularly in the there are indications of morning reports wellbore faiure or tight hole” | regardless of signs updated and changed to | ofinstabilty to better | yyy “Thoroughly describe material | identify changes in Circulated from the well in cutings behavior. each morning report and Photograph it when there are indications of wellbore failure or tight hole.”bOSSSRPETESTIETITsFIsTEsFSsesssssys Reason for fic Category Practice Update Initials “DRILL RATE Al practices are now a part of | Refering tothe PERFORMANCE” the Fast Drill Process. official name of ‘CHANGED TO. ExxonMobi's diling FED “Fast DRILL performance Process” process. “Run maximum gauge length Increasing the on the selected bit that wil | gauge length has stil allow the required proven to be the steerabilty’ updated and | mosteffectve changed to ‘use minimum 4- | design option for in length and dimensional reducing whirl and telief features in gauge design | increasing tool life. of rotary steerable system — | Bits with 1 10 2-in (RSS) bits (e., undercut, gauge lengths have tapered, stepped) regardiess | historically been - of directional company used to achieve the recommendations.” desired steerability. Experience has ‘shown the new practice of tapering ‘or undercutting the gauge diameter allows bits with up to 4-in (101.6 mm) to be equally steerable.fo Category Practice a ae " | initials OTHER Drill and underream (or drill Added comments. wile hole opening) at the ‘concerning 1) the same time, except for increased flow-by specifically analyzed cases, to | area advantage better manage vibrations and | when driling and improve overal driling underreaming, 2) the performance. Driling and tendency for underreaming can also Uunderreaming to WcE provide significantly increased | create vibrations flow-by area around the ‘and, 3) information bottomhole assembly (BHA) | on the recent components making it easier | positive experiences to trip out of the hole and with bi-center bits. reducing equivalent circulating density (ECD), 1@424 24 44.4424444224£4244£2408420 44PORVOO DPFOSPFPRVVVIIIIIVIIVY Items Moved to “Oldies but Goodies” (See Appendix A) Reason for Moving to Catego: Practice Initials eee “Oldies but Goodies” Narrow Manage swab pressures by | Consistently applied MaRGIN optimizing driling fuid where applicable DriLuna properties such that gel sez strengths are flat and non- Progressive. LostReTurns | Execute the Three Step | Consistently applied ANOFRAcTURE | Response" immediately if | where applicable FED CLosurE the annulus will not stand ‘STRESS (FCS) | full after lost retuns. Practices Utiize hydrostatic packers | Consistently applied to control displacement where applicable a when wells wil not stand full. Stuck Pipe | Avoid extended periods of | Infrequent or ‘Avonance | drillstring rotation without | uncommon Woe circulation in packed-off or | occurence partly tuck situations. DRILLING Monitoriplot mud properties | Consistently applied At Fuuns and product concentrations. | globallyReason for Moving to Catego: Practice Initials emery “Oldies but Goodies” Require the mud engineer Determined to be a to record the Diluton Factor | lower impact and the average percent operational practice drilled solids at the end of ‘each interval on the daily. BLE ‘mud report. Use this information to determine the efficiency of the solids control equipment. Use Garret Ges Train Not globally (GGT) to monitor applicable BLE Carbonates in water-based mud (WBM). Utilize sweep reports to To be merged with monitor sweep item on cuttings BLE effectiveness, characterization Implement barite sag Consistently applied monitoring on wells over 30. | where applicable BLE degrees CEMENTING Use pipe movement during | Consistently applied ‘cementing whenever where applicable cB feasible. El reeeeeaeoeoaoaaaqaqaqaqaqaaeecer,Reason for Moving to Category Practice “Qldies but Initials Goodies” Ensure service companies | Consistently applied are rigged up torecord | globaly pressures while displacing with ether ig pumps or service company pumping equipment. the rig pump is performing the displacement, his will oc require te line tothe cement uit is let open, or an additonal pressure transducer installed in the treating line to allow pressure recording for the entre displacement period Wet Use Hye -LL" (Long Lite) | Consistent applied JH oe elements in Hydrl GK and | Where applicable GL annular BOPs. Pump through well control | Consistent applied JH system at frequent intervals. | globally OTHER Follow procedures in the | Intended as a one- KRK new EDC Deilixsw aste | time rollout item; not ‘ngctin Marnaiwhen globally applicable designing and operating waste injection programs.Category Practice Reason for Moving to “Oldies but Goodies” ‘Seek planning input from Dring Technical Operations Support and other Dril Teams, particularly on wells with a Ailing complexity index (DCI) > 4. Consistently applied globallyWorkflow 1. Use the digital drilling data to help identify the root cause of NPT events. (WCE) The digital drilling data (i.e., hook load, RPM, torque, flow rate, pump pressure, block height, etc.) is a valuable tool for analyzing NPT events. All Drill Teams should review and analyze the digital data for NPT events as a standard practice. The review should be performed immediately following the event, or as soon as possible afterward. The Drilling Engineer and Drilling Supervisor should review the digital drilling data (both independently and collaboratively). The objective of the review is to find the root cause of the NPT event, if possible. If the root cause can be identified, operational andlor design changes can be implemented to prevent future occurrences. The digital data can sometimes be “eye- opening" for NPT events such as stuck pipe, lost returns, hole packoffs, etc. Digital drilling data is normally recorded in both footage and time-based formats. It is also recorded for all drilling operations: 1) tripping, 2) circulating, 3) driling, 4) running casinglliner, etc. The time-based data is generally the best format to review as it provides the “complete picture” of what was happening. As a minimum and when available, the following parameters should be tracked and reviewed: 1) hook load, 2) weight on bit, 3) bit depth, 4) block height, 5) RPM, 6) torque, 7) pump pressure, 8) flow rate, 9) ECD (annulus pressure while drilling (APWD)), 10) flow out percentage, 11) PVT total, 12) trip tank #1 and #2, and 13) gas units. Other parameters to review are mechanical specific energy (MSE) and ROP. In addition, downhole acquired data such as gamma ray, sonic caliper and vibrations can be useful in analyzing NPT events. A standard template is available in Rig-Link/Displays/ in Surface Data titled, “Time Based NPT Event Analysis Log.”Note: Downhole tool failures and damaged bits are typically caused by downhole vibrations. Analyzing MSE and the vibration sensor data should also be performed for too! failures and damaged bits to determine the root cause and recommendations for improvements. 2. React to eliminate the causes of “near misses” as rigorously as we react to eliminate the causes of NPT. (SCZ) Many well problems categorized as non-productive time have noticeable early warning signs. Instead of reacting to the NPT after the event, historical and real-time near misses should be investigated to determine their root causes and appropriate measures should be taken to avoid NPT. During the planning phase of a well, the engineer reviews offset well information for non-productive time and plans contingencies for the logical potential risks. However, in addition to actual NPT events, offset well moming reports contain descriptions of historical near misses, which did not become a non-productive time event. These near misses can be indicators of future NPT (e.g., stuck pipe, wellbore instability, lost returns, induced vibrations, and/or drilling fluid anomalies) and should be included in the contingency planning as appropriate. Regardless of detailed planning, uncertainties may precipitate real-time near misses while driling. These should be regarded as NPT and investigated for root cause and appropriate action taken to eliminate future occurrences. >@ORCCAAALAAAAAAAAAAAALAAFSESSETFESETVBOBGHSSVCBosowwsvvvwys Examples of Near Misses and Potential Root Causes Potential Description Root Rossinte Mitigation Cause See: Borehole | * Raise mud weight . Cverpull Instabilit ma iu © Increase hole cleaning cay Ses awareness (larger hole ° Fils size and larger caving) ‘+ Bocky or angular caving © Qattings > % in (12.7 mm) (unless clear PDC bi pattern shown) + Solntery caving © Pack off © Catings loading on ‘shakers higher than ROP © Packoff while reaming © Inadequate formation evaluation ‘* Enlarged caliper logs See also Top 40 “Welbore Stability” and item #19 © Rounded cuttings © Cuttings coming over the shakers in “bursts” + Cuttings loading on shaker lower than ROP would indicate Hole Cleaning | * Increase pump rate Optimize fd theology Consider mechanical hole cleaning devices See also Top 40 Hole Cleaning”© MSE and vibration data ‘© High rate of MWD tool faiure ¢ High rate of BHA, bit or vunderreamer failure Possible Description Mitigation Cause en © Sweep trends © Packoff while reaming ¢ Unusual friction factors ‘© Torque fluctuations © Tight hole © Overpull + Bridges © Pack off Ballooning Formation © Proactively treat lower Integrity integrity with FCS pill . Lost retums ‘See also Top 40 “Lost . Hole taking @ “drink” Retums" and item #20 © Bitdamage pattems Vibrations | ‘See Top 40 items #28 through 31, and #33PIDIODIDVDIDIVIDVIIVIIISVIVIVY Descripti ae Eoasiple cern e Mitigation Cause Unusual friction factors | Dring fuid iter | See Top 40 items #23 and #26 cake anomaly Seepage losses Torque fluctuations TREAT NEAR MISSES AS NPT!Zeer ee eee eee eee eee eee Hole Cleaning 3. Use onsite torque and drag (T&D) monitoring while drilling, tripping, and running casinglliners in wells over 40 degrees. (WCE) Onsite torque and drag monitoring is a rig-site process that involves obtaining, recording, plotting, interpreting and acting upon torque and drag data. This process is used for monitoring the hole condition (i.¢., how clean the hole is and signs of stuck pipe) and providing insight to remedial actions. This process can be implemented for drilling, tripping in or out, reaming in or out, running casing or liner, drill pipe conveyed logging, running tubing, etc. When used accordingly, onsite T&D monitoring can be a valuable tool for the Rig Site Supervisor to monitor daily operations. In addition, the collected data forms a basis for the Drilling Engineer when performing post-well analysis and/or future well planning. This process should be used on wells over 40 degrees, anytime IHQ-type hole problems are anticipated, on extended reach and horizontal wells, and when pushing the rig's capability limits. Of note, Drilling Technical has developed general guidelines for onsite T&D monitoring and recording. See Drilling Technical GlobalShare / Library / Elks / On-site Torque and Drag Monitoring Procedure and Plotting Spreadsheet for these guidelines. 4. Drop down and MR MC rather than POOH through tight spots with greater than 30k Ib (14 metric tons) overpull in wells over 40 degrees. (WCE) Attempting to pull through tight spots is risky on high angle wells. If the tight spot is caused by cuttings beds, then there is a high risk of mechanically sticking the BHA. The recommended approach is to set a tripping overpull limit such as 30 to 35k Ib (14 to 16 metric tons) and usethis limit to trigger the “drop down and MR MC" procedure. If the overpull limit is reached while tripping, then lower the drill string back down one to two stands to get the BHA below the potential cuttings bed prior to initiating circulation or rotation (do not want to packoff around the BHA due to fluidizing a deep cuttings bed). After dropping down, slowly initiate circulation and rotation and bring them up to full speed. Maximum. rotation, maximum circulation (MR MC) for +30 minutes and then attempt to pull back through the tight spot on elevators/top drive without circulation and rotation. If the tight spot has disappeared, then it was probably cuttings beds and some additional MR MC bottom ups may need to be performed. If the tight spot remains, this is an indicator of reduoad hole size and additional hole maintenance steps (e.g., backreaming may be required). Backream only what is required. One tight spot does not mean itis necessary to backream out to the casing shoe. Backreaming is also a risky operation. The preferred method for tracking trips is to use onsite torque and drag monitoring plots, which provide a full picture of the trip, including changes in trends, deviations from predicted loads, and tight spot identification. Note: The recommended overpull limits are standard limits that should work for all drill well cases. Each Drill Team should evaluate their experiences and, if deemed worthwhile, revise the limits for the well conditions and rig capabilities. Higher limits may be warranted besed on field experience. Of note, be sure to consider the drill pipe buckling limit ‘when setting overpull limits. If you pull into a tight spot that requires slacking off a weight that buckles the drill pipe, then you may not be able ‘to slack-off and move the pipe downwards. 5. Eliminate backreaming out except when hole conditions prove the need in wells over 40 degrees. (WCE) Backreaming out is a risky operation that should only be performed when there is insufficient MR MC to effectively clean the hole or when tight holerEeVvrvrvvVvVF FTF VF VFVTVV~we~VFeVvVIVIVITZ ST problems prohibit safe tripping on top drive/elevators. Utilizing sufficient MR MC with multiple bottoms-up cycles while monitoring the shakers for cuttings retums is the preferred method for effective hole cleaning ‘operations. If MR MC does not adequately clean the hole to safely trip or if tight spots are encountered while tripping, then backreaming may be required. If backreaming is required due to poor hole cleaning, then consider backreaming out until the well angle is approximately 40 degrees, or at least back to the previous casing shoe (be careful here because cuttings beds do not distinguish between cased hole and open hole). Hole enlargement (primarily from wellbore instabilty) can easily create situations where poor hole cleaning occurs. If backreaming is used only to eliminate a tight spot, then backream only the interval that is troublesome. In either case, use the recommended backreaming practices in Practice #6. Note: It is a common practice to backream out for open hole completions and when running “floated” casing strings. Open hole completions generally require “no-cuttings bed" if the completion requires gravel packing and/or if the completion assembly does not have any method of washing down. When casing is floated, there should be minimal to no cuttings bed. Casing floatation does not allow for washing down. 6. When backreaming is required, follow proper IHQ procedures to minimize packoffs and stuck pipe in wells over 40 degrees. See detailed Top 40 discussions. (WCE) Improper backreaming techniques (i.e., backreaming too fast, pulling prior to reaching full circulation and rotation speeds, initiating circulation and rotation in a thick cuttings bed, not circulating after each stand is backreamed, etc.) can and usually does lead to packoffs, lost retums, and stuck pipe. Wellbore instability also plays a major role in backreaming success. Wells that have wellbore instability problems almost always have backreaming problems. Packoffs often occur while backreamingwhen the top stabilizer/drill collar passes from an enlarged hole area into a normal hole size due to the high volume of cuttings flow through the restriction. The resulting pressure surges may lead to wellbore instability problems (pressure cycling can damage the wellbore integrity). If backreaming is required, use the following practices: A. Fully discuss the procedure, risks of backreaming and contingency plans for problems with all drillers that will be on the brake during backreaming operations. Discussion should include tool pushers, directional drillers, and the EMDC Drilling Supervisor. Show EMURC's Hole Cleaning Video. B. The EMDC Drilling Supervisor or appointed representative is to be on the rig floor at all times during backreaming operations. C. During crew changes, circulate and reciprocate while swapping personnel. Review procedure and contingency plans with the new crew before resuming backreaming. D. Record and plot pick-up hook load and torque trends for each stand. Use more frequent and/or longer circulation and rotation periods if increasing pick-up or torque trends are observed. E. When separate trips are made to clean the hole, use a minimal BHA. specifically designed for backreaming operations (i.e., bit or hole ‘opener with maximum nozzles, stabilizer, one DC, stabilizer, three joints of heavy weight drill pipe (HWDP), jars, and six joints of HWDP)..FROROSOGPTFTFPFIIFIIIVIssvsasvsvv—vIsIwwsy Note: A smaller outside diameter (OD) BHA may be used if hole swellingfightness is not an issue (a smaller OD assembly may require a slower pulling speed to fully clean the hole). Prior to starting the backreaming operations, MR MC one to two bottoms up while reciprocating the drill string. It is not crtical to MR MC three to five bottoms up since backreaming operations will be taking place. Use RPM whirl test results and/or BHA vibration sensors to optimize MR MC rotary speed with respect to vibrations. While circulating and reciprocating, do not stroke the bit closer than 5 to 10 ft (1.5 to 3 m) from bottom to ensure there is sufficient room to jar downward if the pipe sticks. Set the drill pipe low in the slips so the top stabilizer is positioned below the reamed cuttings bed while making the connections. Break ut the stand and rack it back. After each connection and before starting backreaming, bring up pumps slowly to a moderate speed to ensure returns are flowing free. Slack-off and slowly start rotating the string. Bring pumps and rotary up to full speed. If differential sticking or ECD is a concer, then initiate slow rotation first to keep the pipe moving and/or more soflly break the mud’s gel strengths. Allow the system to reach a steady-state pump rate, pressure, and rotary speed to obtain indicators that are more consistent. Backream at a pulling speed of no faster than five minutes per stand. Watch torque and standpipe pump pressure gauges at all times while backreaming. Adjust pulling speed based on torque and pressureresponses. Use ToolPro Hole Cleaning software to calculate minimum safe backreaming speeds. Of note, backreamirg out in difficult hole conditions requires extra time and patience. It is common to require 45 to 60 min to backream up one stand under these conditions. Do not get in a hurry. Backream at 80 to 120 RPM. Adjust speed as needed. High RPM is not critical when backreaming but may be used if hole conditions permit. Backreaming can cause severe vibrations due to RPM induced whirl, which in turn may enlarge the hole depending on the side cutting ability of the bit. Always perform an RPM whirl test to find the “sweet spot” to minimize RPM induced whirl. Plot torque vs. RPM starting at about 80 RPMs and increasing by about 10 RPMs each time. If whirl is initiated, then a change should be seen in torque trend (i.e., slope change) that plots as a significant increase in torque and/or erratic torque (not steady). Avoid backreaming at RPMs that induce whirl. In addition, if the BHA has vibration sensors, use the vibration readings to manage whirl. |. After completion of each backreamed stand and prior io racking back each stand, circulate, rotate, and reciprocate the last pulled joint for three to five minutes to push the cuttings bed above the BHA. Ream up as high as the derrick height will allow. Repeat steps H through M as you backream out of the hole. At about half way out, consider cleaning up the hole to reduse Cuttings load-up. When the hole angle reaches approximately 40 degrees, stop backreaming operation and clean up the hole with MR MC for thr: LBRSKRVAVARAAARAARAAARAARAVORP ITFIFFPAIIAISAIOMV9IA9 TBA vv VVVVyY to five bottoms up. Then POOH on elevators or top drive (no pumps and no rotation) watching for increasing pick-up drag trends. Use RPM whirl test results and/or BHA vibration sensors to optimize MR MC rotary speed with respect to vibrations. Q. While backreaming, if the pipe tries to stick or the hole starts to packoff, immediately lower the string back down before trying to deal with the problem. Never pick up; this may result in a complete packoff. Rotate and reciprocate to reduce the cuttings bed prior to attempting to pull back into the packoff area. R._ If the pipe becomes stuck, attempt to jar down — not up. Maintain a single joint in the V-door for emergency pick-up to start the lowering process. If successful, lower an additional one to two stands to got BHA safely below any cuttings bed prior to reinitiating circulation, S. If pump or top drive problems occur while backreaming, lower the ‘string so the BHA is not positioned across permeable sands (use single or one to two stands if possible). Discuss options and risks associated with shutting down to make repairs. Generally, the risk of sticking is minimal in NAFs if the BHA is not in a permeable sand. Risks are greater in WBM. The cuttings should not slide downtole at angles above 60 degrees. After repairs are made, do not attempt to POOH through a backreamed cuttings bed without MR MC to clean the hole first. 7. Use ToolPro Hole Cleaning software for well planning and for surveillance checks when parameters change. (WCE) The ToolPro Hole Cleaning software should be used to confirm sufficient hole cleaning capability. The ToolPro Hole Cleaning model is designedfor both verticallow angle wells and directional wells over 40 degrees. For vertical/low angle wells, use the transport ratio (TR) to confirm your driling, circulating, BHA, and mud rheology parameters provide sufficient hole cleaning. The transport ratio should be greater than 0.5. For wells over 40-degree inclination, use Hole Cleaning Ratio (HCR) along with Cuttings bed height and cuttings concentration to confirm drilling, circulating, BHA, and mud rheology parameters provide sufficient hole cleaning. HCR should be 1.1 or greater. ToolPro is an IHQ technology that can assist the engineer plan the hole cleaning and hydraulics program and do surveillance checks when parameters change while driling. It can also be used to optimize dil rate, mud properties, bit selection, and pumping and backreaming out operations with respect to hole cleaning performance. ‘Note: There are other hole cleaning (hydraulics) programs available from service company vendors that perform similar types of analysis like ToolPro. ExxonMobil has not reviewed/approved these vendor-supplied programs; however, several Drill Teams have commented these programs provide a better ‘daily surveillance” check regarding hole cleaning operations. Drill Teams may use these programs at their discretion for hole cleaning analysis and surveillance; however, they should be used in conjunction with ToolPro, 8. Focus on 6-RPM reading in addition to yield point for hole cleaning. (BLE) The 6-RPM reading is the preferred indicator for cuttings/cavings transport. Equally important are the gel strengths for cuttings suspension when the pumps are off. A driling fluid’s gel strength has to be sufficient to suspend cuttings/cavings during connections and other static periods. Elevated gel strengths can also offer resistance to avalanching in enlarged areas.FOSDOTTVVFGOVOTVTOVOVTVTTeTve In water-based mud, the 10-second gel strength is approximately equal to the 6-RPM reading. However, the lower limit of a 10-second gel strength required to suspend cuttings/cavings/ weighting material is 5 to 6 Ib/100 ft? (2.4 to 2.9 Pa). In larger diameter holes with higher 6-RPM readings, the 10-second gel strength may be higher (double or triple). In addition, the 10- and 30-minute gel strengths are usually higher, but should be flat and non-progressive. Choose mud additives and manage solids content carefully so low-end theology is increased with minimal increase in high-end values such as 600 RPM reading and plastic viscosity. 6-RPM Guidelines Vertical wells and wells with angle < 30 degrees; mud weight < 15 Ibigal (1.8 sg) At minimum, maintain the 6-RPM reading near or equal to hole diameter in inches. For example, in 12%-in (311.2 mm) hole, a 10 to 12 would be appropriate, in 8%4-in (215.9 mm) hole, a value of 7 to 9. An exception exists for very large hole sizes (217% in, 444.5 mm). In most cases, large holes are being cleaned when the 6-RPM reading reaches the high teens to low twenties. Vertical wells and wells with angle < 30 degrees; mud weight > 15 Ib/gal (1.8-2.3sg) In wells with high mud weight, hole cleaning receives a boost from buoyancy. In addition, ECD vs. fracture margins are smaller. In these cases, the 6-RPM reading may need to be lower. For example, in a 6%-in (171.5 mm) hole a minimum value of 4 to 5 can still provide adequate hole cleaning while minimizing ECD effects from viscosity.As well angle exceeds 30 degrees, hole cleaning requirements will increase and one needs to move toward the higher angle 6-RPM recommendations. Well angle > 40 degrees; mud weight < 15 Ib/gal (1.8 sq) Maintain the 6-RPM reading 1.0 - 1.5 X hole diameter in inches. In 8%-in (215.9-mm) hole and 45-degree angle, a minimum value of 9 may be adequate. However, at 80 degrees, the number may need to be 11 to 12. Hole conditions will dictate the final value. Exception: High mud weight and small hole size. With mud weight 2 15 lbigal (1.8 sg), cuttings buoyancy will assist hole cleaning. In addition, small holes typically have high annular velocity, which also helps clean the hole. Under these conditions, the 6-RPM reading can sometimes be run less than hole diameter with no adverse effects. 9. Set casing on bottom or as close to bottom as possible. Minimize the rathole below the casing shoe to help mitigate hole cleaning problems. (WCE) When mandrel casing hangers are used, always plan for an allowable rathole so there is room for error in landing the casing. No one wants to tag bottom early and have the casing mandrel sticking up above the wellhead. However, leaving rathole below the casing shoe creates an automatic hole cleaning problem. In addition, if this interval is drilled with a non-inhibited fluid such as a typical water-based mud, the exposed rathole has a high probability of enlarging further. This enlarged hole below the casing shoe is just like any other enlarged hole area. It traps cuttings and cavings. It can be very difficult to effectively clean. It makes tripping through the interval difficult. It can make it difficult to pa: successive casing strings through it. It leads to packoffs and possibly los returns.FORT OOPOVPIIVIFIVIssesygvvygueuvs There are different Drill Team practices for the length of acceptable rathole. Some are comfortable with approximately 15 to 20 ft (4.5 to 6 m) while others want enough room for an entire casing joint while others will work the details and plan for 10 ft (3m). The correct answer should be “work the details” and keep it to a minimum such as 10 to 15 ft (3 to 4.5 m) or less. e Tape-strap the casing and strap it again, if necessary. Be sure to account for connection make-up loss. © Count and tally the casing and count and tally it again, if necessary. e Use laser distance measuring devices in conjunction with tape strap measuring. If the numbers do not agree, re-measure. * — Strap the drill string on the final trip out of the hole to run casing. * Be prepared to wash-down if casing tags up shallow. Wash down the last joint. ‘© Check the pipe stretch of the drill string on the final trip out of the hole. Drill pipe stretch will generally be slightly longer than casing stretch due to the heavy BHA components on the end of the drill string, although in high angle wells, this weight is supported by the borehole and the delta stretch may be nullified. © Calculate and compare the drill sting stretch and the casing string stretch using ToolPro 2007 when it is released. The software includes a stretch design calculation for the given load conditions in the torque and drag (analyze section). Use field experience to track “planned depth, actual tally depth, and actual drilled out/tag bottom” depth. Adjust as required to achieve the desired minimum rathole.« When possible, use slip-type hanger systems such that casing can be set on bottom, especially in fields prone to wellbore instability. If the casing tags up high and the casing cannot be washed or worked down to bottom, potentially leaving an unstable shale interval exposed. the Drill Team needs to consider the implications of this exposed shale. Several wells have been lost due to the inability to stabilize this shale and effectively clean the rathole. The best business decision may be to pull the casing back out and recondition the hole, not just set casing leaving the shale exposed to the next hole section. © — If casing/iner is floated in, be sure to account for casing length growth 2s the casing is filled with mud. The pipe will generally elongate due to the changes in pressure, temperature, and loads. 10. Use mechanical cuttings bed “stirring” tools to help improve hole cleaning in wells over 40 degrees. These tools will be beneficial in hole sections that are difficult to effectively clean {ie., big holes, enlarged holes, limited hydraulics, etc.) (WCE) Cuttings bed stirring tools (subs or joints) provide improved hole cleaning performance, espedally in big holes (14%in (374.7 mm) and larger), enlarged holes (wellbore instability), and holes drilled on the low end of the recommended MR MC parameters. Cuttings bed stirrers act like the stabilizers in the BHA. They mechanically ‘throw’ the cuttings bed into the flow stream providing additional energy to get the cuttings out faster and reduce the cuttings beds. PSHSOLSHKERARATDRADAALRARIADFHFFFHGFFFFICESSESESCseeesessweyv Drill teams that have used these tools report: © Cuttings getting to the surface looking like cuttings instead of grindings Eliminated and/or significantly reduced cuttings beds/dunes encountered in previous wells when tripping pipe Reduced casing running friction factors and smoother casing runs ‘© Higher percentage of cuttings returns vs. hole drilled © Overall general improvement in hole cleaning performance « No adverse effects such as increased torque and drag, casing wearldamage, mechanical failures, etc. Of note, the additional mass/design of these tools will increase ECD; however, the reduction in cuttings bed height should provide for more flow-by area, which should help offset the ECD increase. Note: most experience has been with 12%-in (311.2 mm) and larger hole sizes where ECD is generally not a concern. There are several options for cuttings bed stirring tools. There is “bladed drill pipe,” which looks like a drill pipe joint-long integral blade stabilizer (but buill on a drill pipe body OD base). There are specialty rental drill pipe subs 3 to 4 ft (1 m) in length that look like “fancy” stabilizers. There are specialty rental drill pipe joints with built-in (+/-3) “fancy” stabilizers. The statilizer/blade OD on these tools is generally larger than the drill pipe connection OD but significantly smaller than the hole size (ie., 8-in (203.2-mm) OD blade with 7-in (177.8-mm) OD connections on a 5Y-in (139.7-mm) pipe base for 12’%-in (311.2-mm) hole). EMDC does not have enough experience to recommend one option over the other, except to ‘say that most of our experience has been with the latter style (drill pipe joints with built-in stabilizers). Of note, the fancy stabilizers are typicallyproprietary designs intended to improve cuttings bed agitation. EMDC has not tested these designs; therefore, cannot comment on the advantages or disadvantages when compared to each other or a regular stabilizer. For the tools to be fully effective, they need to be spaced at one every two stands (up to a maximum of every four stands) of drill pipe in the high angle portions of the well (ie., greater than a 40-degree inclination in the build section, tangent section, horizontal section, etc.), and in both cased and open holes. In high-angle wells, cuttings do not stay suspended in the flow stream — they gravitate to the bottom of the hole to the cuttings bed. The gravitation drop time is dependent on several parameters such as flow rate, mud rheology, cuttings size/weight, hole size, etc. Generally, Cuttings will drop out of the flow stream in 100 to 300 ft (30 to 90 m) of Circulating distance, if not sooner. The cuttings stirring tools help get the Cuttings back into the flow stream faster and more often. In addition, there is a positive benefit of using these tools when backreaming out. During backreaming, the entire cuttings bed is pushed up the hole ahead of the BHA creating a higher cuttings bed. These tools provide the same benefit of improved hole cleaning during this operation, allowing for a smoother, less troublesome backreaming operation and possibly faster backreaming, Another benefit of these tools is they should help “clean” enlarged hole intervals by helping stir up the “higher cuttings beds” that form in enlarged hole areas. When holes enlarge, they creale intervals of reduced annular velocity and higher cuttings beds when compared to gauge hole intervals. The stirrers will help agitate the cuttings in the enlarged areas and get them in the flow stream, possibly making for an easier trip through this interval.FHOVIFIIVIIFIVIPIVIVVVIVIVVuVvyvuuy 41. Do not rely on sweeps to clean your hole. (SCZ) ‘Sweeps have historically been used to aid hole cleaning in low-angle and medium-angle hole sections (vertical up to 40 degrees). In these wells, sweeps support carrying cuttings or cavings out of the hole where little or no cuttings beds form. For example, sweeps have been used to clean Cuttings from deepwater risers and large boreholes. In vertical to low- angle wells, high viscosity sweeps have been shown to be successful. ‘Sweeps have also been applied in high angle hole sections (greater than 40 degrees). Sweep monitoring and dedicated sweep reports have shown increased cuttings to the surface with the sweeps. When applied to these hole sections, tandem sweeps — low viscosity pill followed by high mud weight pill (2 to 3 Ib/gal (0.24 to 0.36 sg) above the static mud weight) — have shown some effect. Care should be taken to ensure the ECDs while pumping the sweeps do not exceed integrity. Regardless of the outcome, these sweeps may provide a false sense that sweeps are cleaning the hole. Itis important to remember: © Cuttings carried out by a sweep may only remove the cuttings from the uppermost 2,000 to 3,000 ft (600 to 900 m). « Even when the sweep report indicates a significant increase in cuttings/cavings being carried out for several minutes, this short-term increase may represent less than 10 percent of the cuttings left behind.¢ For example: A 3-in (76.2-mm) cuttings bed in an 8%in (215.9-mm) hole has an approximate volume of 22 bbi/,000 ft (3.5 m'/305 m), Whereas a 50-percent increase in cuttings for five minutes may Temove less than 2 bbl (0.3 m3) of rock. © Similarly, if the sweep no longer produces an increase in cuttings, the conclusion that the hole is clean may be incorrect. Cuttings beds are being eroded by pipe rotation and fluid velocity and depencing upon hole size, hole angle, sweep volume, and sweep viscosity, cuttings/cavings may not be effectively retumed to the surface by the sweep. The purpose of this discussion is to point out the limitations of this technique and not eliminate them entirely. Accurate characterization of material (shape and size) removed from the well is an excellent means to determine whether the hole is cleaned, or whether borehole instability is indicated. These observations should be documented on the sweep report. PPPOPPOPeeeeeececenaesennFReSsSCFTVDIFFTVOPGPSFTFGFTOGCPTVsgqgwsewwwews Wellbore Stability 12. Every drilling program should address wellbore stability and include a wellbore stability chart on wells or fields with a risk or history of borehole instability. (MJT) Stability analysis is generally recommended for all wells with over 40 degrees of inclination, when experience shows problems in lower angle wells, and in areas of tectonic stress (proximity to mountains, salt domes, active faulting) regardless of hole angle. A section on wellbore stability should be included in every drilling program. If wellbore stability is not a determining factor in drilling fluid density or design, this should be stated along with the reasons. If the mud weight program has been determined by wellbore instability, a wellbore stability model should be included in the drilling program. This model should have a plot of wellbore collapse gradient or breakout initiation gradient vs. depth, as well as pore pressure and fracture gradient. The purpose of wellbore stability analysis (performed with the ToolPro software) is to predict the mud weight required to prevent catastrophic collapse of the borehole. More lengthy analyses are usually done by EMURC, although Drilling Technical Operations Support can update certain ongoing analyses, perform checks on an urgent basis pending EMURC analysis, and assist in implementation and surveillance of a wellbore stability design.The key actions the Drill Team must take are: A. Work with EMURC or Drilling Technical Operations Support to acquire a set of shale cuttings from all potential problem zones for special surface area analysis (i.e., Dielectric Constant Measurement (DCM) at EMURC or one of several licensed labs B. Gather all available offset leakoff test data C. Obtain several representative density logs D. Gather available offset well data that may give information on wellbore condition The cuttings are measured for shale specific surface area, which is used to estimate the compressive strength of the material from an extensive database of shale types. Wellbore collapse is then predicted to occur when the stress around the hole is calculated to exceed the strength of the rock, Obtaining a wellbore stability analysis from EMURC requires one to two months and this is perhaps the longest lead-time item of all the IHQ- related planning activities. The work is needed early because the results may have a significant impact on the well plan, including changes in mud type, wellbore trajectory, and casing setting points. Drilling Technical Operations Support can continue to assist in day-to-day implementation and surveillance of a EMURC model if necessary. PHCHLHKRLHELHHAKEARARBADRAARAFHFFSFGPVGIAP@Fswssesessesesewwvwsvs 13. Collect geomechanics data for all new fields and existing fields with increased well complexity (drawn-down sands, longer reach, and higher angles). (MJT) During development planning of a new field, it may not be apparent that wellbore instability will be a concern, especially if costly problems were not incurred during exploration drilling. Even established fields may give little indication that wellbore stability design is necessary. However, these problems often appear during field development or expansion as increasingly higher angle wells are drilled. In order to react to these problems more rapidly, it is good practice to maintain a local database of shale formations with corresponding DCM shale analyses, a database of all leakoff tests (and possibly several extended leakoff tests for minimum stress determination), and digitized density logs. The ‘eakoff ‘test/minimum stress database by itself is good practice apart from ‘wellbore stability diagnosis because it will set a reference for expected shoe strengths and benefits to be expected from FCS technology. Bedding planes of potentially weak formations should also be identfied in ‘the field so wells can be planned to minimize the angle of incidence with these zones. Drilling Technical Operations Support (in collaboration with EMURC) can assist in establishing a standard format for the database and in selecting and analyzing the shale for populating the database, 14. “Slow pump out” during trips or “increase the mud weight” prior to tripping out on wells prone to hole collapse - “swabbing action” during trips may lead to wellbore instabilit Tripping out of the hole causes a swab effect on the wellbore (i.e., loss in hydrostatic pressure). Pressure drops equivalent to 1 Ib/gal (0.12 sg) in mud weight have been recorded on downhole pressure-while-drilling tools in ExxonMobil wells. These pressure drops can lead to wellbore instability (ie, hole falling in, cavings) during the trip out of the hole. There have been cases where the well was MR MC with multiple bottoms up with littleto no cavings observed at the surface. The drill string was then tripped ‘out smoothly for 10 to 15 stands until a tight spot was encountered. Upon MR MC bottoms up, the well unloaded excessive amounts of cavings leading to extended hole conditioning and sometimes stuck pipe. This ‘swab-induced wellbore instability is only a concern in wells where the drilling mud weight provides borderline stability for the wellbore. When drilling in fields where wellbore instability is a known problem and similar tripping problems have been experienced, “slow pumping out” and/or “increasing the mud weight" may be a viable method to mitigate the swab effect. Do not think that swabbing is not occurring in the wll just because there is no flow-back on the annulus, the well is taking the proper amount of fluid, or the drilling fluid properties are thin. The well swabs every time the drill string is pulled up. The amount of the swab depends on several factors: the bypass area around the BHA, pulling speed, length of drill pipe, height of the cuttings bed, driling fluid rheology properties and gel strengths, etc. Annulus pressure while driling (APWD) tools can be used to determine the amount of the swab experienced on trips. The tools must be set for recording the pressure data while in tripping mode (i.e., no circulation) in “time based” format. Depending on the capabilities of the MWDIAPIND system, this data can be either pumped up at connections or downloaded upon reaching the surface. If APWD tools are not available, then use Surge/Swab software, such as Surge 1.21, to calculate the swab effect. Slow pumping out is a process that negates the swab effect. The procedure requires pumping out of the hole while pulling on elevators or top drive (without rotation) at a circulation rate that just fills the void space below the bit created by pulling the drill pipe out of the hole. The circulation rate is a function of the pulling speed and the volume of steel (drill pipe) removed. Generally, pulling at 3 to 4 min/stand while pumping out at 2 BPM (0.32 m/min) is sufficient. This can be a slow process but it has proven to virtually eliminate all swab. ~— eee eww ewww mene eo enonPE eTrT TTI FTFIFFVCGFCVTCVCVCVVVIVVNY There is some added risk to slow pumping out, just like there is when backreaming out; however, slow pumping out reduces the risk of packing off and losing returns that can occur while backreaming. Slow pumping out places far less shock load to the formation when packoffs occur than backreaming out at 1,000 GPM (3.8 m/min) and 120 RPMs. However, good tripping procedures must be in place while slow pumping out. MR MC with multiple bottoms up before tripping (reduce the cuttings bed to a minimum). Use RPM whirl test and/or BHA vibration sensors to optimize MR MC rotary speed with respect to vibrations. Set overpull limits (such as 30k Ib (13.6 metric tonnes) overpull) for the trip out. Tight spots are assumed to be cuttings beds. Drop down, bring up pumps and rotary slowly to full speed and MR MC for 30 minutes to displace the cuttings bed. Afterwards, shut down the rotary and return to the “slow pumping out” process. Watch pump pressure for signs of packing off; however, at slow pump rates and low circulating pressures, packoffs will not be as obvious. Like backreaming, the Drilling Supervisor or appointed representative ‘should be on the rig floor at all times during the slow pump out of the hole operations. Use the “flow show” as “best indicator’ of the hole packing off. A drop in the returns flow rate is a sign of packing off. Best practice is to assign a person ‘full time” to watch the flow show and be in direct communication with the driller. Always stack off and drop down at the first sign of packing off.Remember, slow pumping out may actually displace some cuttings into the flow stream and deposit them above the BHA. This may build up a cuttings bed that is no longer safe to trip through. Tight spots and packing off are indicators thet the cuttings bed may be high and that MR MC may be required to reduce the cuttings bed toa safe tripping level. © Atthe end of the slow pump out trip, MR MC one to two bottoms up prior to initiating normal tripping operations to ensure the cuttings bed is reduced to a minimum level. Note: Just slow pumping out to the previous casing shoe is generally not sufficient. The swab effect occurs throughout the entire trip out. How far “up the hole” to pump out is a function of the pulling speed, drill pipe size, hole size, mud rheology, bit depth, etc. The swab effect can be modeled with software to estimate the hydrostatic head loss at any given depth in the well; however, using APWD data acquired on trips will give a more accurate answer on the head loss. These measurements should be taken at typical pulling speeds to be representative. Then the Drill Team must decide how much hydrostatic head loss that they are willing to live with. Remember, EMURC’s recommended mud weights in their wellbore stability studies do not account for swab effects. © If this process is troublesome and appears not to be improving trips, then backreaming out may be required. Instead of slow pumping out, the swab effect can also be countered by increasing the mud weight prior to tripping out of the hole. Increasing the mud weight does not eliminate the swab effect like slow pumping out does, but it can compensate for some or all the loss in the hydrostatic. head during the trip. Use the APWD trip data (or Surge/Swab software calculation) to determine the swab effect. If the loss is equivalent to say ~__—_2_ =e ea ew een eee ena he2OODR'D DD0.5 Ib/gal (0.06 sg), then raise the mud weight, if the fracture gradient and hole conditions permit, by 0.5 Ib/gal (0.06 sg) prior to the trip out. Note: Increasing the mud weight prior to tripping out may be better suited for the final trip out of the hole to run casing, whereas slow pumping out may be better suited for all other trips. Note: EMURC’s wellbore stability modeling recommendations are typically based on an allowable breakout amount (i.e, 15 percent by volume or 90 degrees by borehole angle). The mud weight recommendation assumes the equivalent hydrostatic head or greater is always maintained on the wellbore. It does not take into account the loss in hydrostatic head due to ‘swabbing on trips. Therefore, to maintain the equivalent hydrostatic head ‘on the wellbore, the mud weight must be increased by either the ‘equivalent swab effect loss or the swab effect loss must be eliminated by ‘slow pumping out. ‘Slow pumping out and/or increasing the mud weight are NOT processes to be used on all wells. However, if your wells experience hole enlargement or have signs of wellbore instability on trips (ie., cavings, hole problems), then this is a process that may help. 15. Implement sonic caliper surveillance practices in wellbores that penetrate weak, failure-prone shale. (MJT) Loggirg while drilling (LWD) suites usually contain an ultrasonic caliper to correct logs for varying borehole quality. This caliper log can be used to monitor hole condition across shale that has been identified as potential wellbore failure horizons to qualitatively gauge borehole enlargement. ‘When part of an LWD or MWD string, it should be used to assess time- dependent degradation of the weakest shale that is exposed by making repeated passes at different times. In areas where borehole instability is a demonstrated problem, running the tool can calibrate borehole stability models, and allow field corrections to be made to mud weight programs.DCM measurements will promote the most efficient use of the tool by ‘identifying formations that warrant examination. 16. Thoroughly describe material circulated from the well in each morning report and take photographs when there are indications of wellbore failure or tight hole. (MJT) The shape of rock circulated from a wellbore can be used to determine if hole failure is occurring as well as determine the quality of hole cleaning. Cuttings from PDC and roller bits have characteristic shapes that are distinct from cavings from wellbore failure. Cavings tend to be variously blocky, elongated, and generally larger than cuttings. Spalling shale from underbalanced conditions has yet another distinct form; they tend to be splintery and sharp if they emerge well preserved. Rounding of cuttings or Spallings indicates long residence time and possible poor hole cleaning. Cuttings should be described in the morning reports whenever material is circulated from the well, including driling, circulated, and pumping sweeps. The description should include the size and distribution of the material (e.g., 25 percent % to -in (6.4 to 12.7 mm), 75 percent to 1-in (12.7 to 25.4 mm)), whether the material is cuttings or cavings, lithology of the material, shape (blocky, rounded, angular, etc.), and amount (light, normal, heavy). Ideally, cuttings weighing and/or accounting should be used to track cuttings storage or excessive enlargement. If cuttings weighing is being conducted, a volume surplus/deficit should be reported. Fill out a sweep report on every well using sweeps. The report is available from Driling Technical Operations Support, GlobalShare, or in the EMDC Drilling IHQ Manual. Photographing the material from the hole will allow all parties to view the same information prior to making decisions concerning hole problems. Remember, "A picture is worth a thousand words." -~---_sae eaaonmeonannannaannanaaaanaea17. Proactively maintain sufficient mud weight from the start of each interval to prevent hole enlargement. (MJT) Hole enlargement is one of the major root causes of non-productive time (NPT) worldwide. In low-angle wells, enlarged areas reduce the annular velocity resulting in poor cuttings transport. Cuttings have a difficult time circulating out of these enlarged sections and packoff around the drill string when the pumps are stopped. In high-angle wells, the enlarged areas accumulate sizeable cuttings beds that result in stuck pipe while tripping out of the enlargement. To prevent these effects, it is imperative to drill a wellbore as close to gauge as possible. Unlike other driling problems, enlargement is irreversible. Once a section of the wellbore has broken out, that section can never be gauge again. Hole cleaning problems created by unplanned enlargement will not be fixed once the mud weight is raised since the hole is already enlarged. Signs of wellbore instability should be recognized as permanent downhole enlargement, which must be handled through operational practices like backreaming, slower tripping operations, and pumping sweeps. These mitigations can be time consuming and costly. Instead of allowing enlargement, minimize wellbore breakout by running the mud weight required for no breakout for the entire hole section (or if not feasible, the highest mud weight possible) from the start of the interval. Avoid waiting for signs of instability before building mud weight, since enlargement will already have occurred before there is an opportunity to react. The mud weight should be selected by identifying (by leakoff test) the integrity of each hole section and accounting for ECD. Concems about lost returns, reduced ROP, and differential sticking can be addressed with operational practices and drill string design, all addressed elsewhere in this document.48, React immediately to signs of instability by increasing mud weight andior inhibition to prevent further hole enlargement. Adjust hole cleaning and tripping practices to account for known enlargements. (MJT) When wellbore instability is detected, it is critical to react immediately to prevent further enlargement that could result in severe hole cleaning problems and potential loss of the well. Definitive indications of wellbore instability include cavings circulated from the well, fil on bottom, surplus material circulated from the wellbore, and increase in hole volume. Often, these signs are accompanied by tight hole, packoffs, excessive torque, loss of directional control, failure of downhole tools (often from breakout- induced whit), and unexpectedly poor hole cleaning. If hole enlargement is suspected and the BHA includes LWD tools capable of providing a caliper, obtain and review the caliper to determine hole enlargement over time and pinpoint problem intervals. Keep in mind this is not the final driling caliper, which must be obtained on a subsequent logging run. ‘As open hole time increases, most severely with water-based drilling fluids, hole enlargement tends to worsen, Urgent action is required to counteract wellbore instability. The best and most effective option is to raise mud weight. In some cases, where margins are tight, raising mud weight may require a decrease in resulting ECD by reducing ROP and/or flow rate. Hole cleaning models should be consulted before taking such action. Other options, including increasing the inhibition level of the diling fluid andior swapping a water-based fluid out for a NAF are rarely effective once enlargement has begun. Regardless of whether action is taken to prevent further breakout, operational practices should be adjusted to account for the fact that the wellbore has been enlarged (and possibly continues to enlarge). ---- ee eam m mmm mn oonePOCO FTTFTFTTIFTVFCVTCCVTwVvwvwvvwvwvwvwvwy To clean the enlarged hole, first maximize flow rate then increase pipe totation. If more improvement to hole cleaning is needed, increase the drilling fluid 6 RPM to 1 to 1% times the hole diameter in inches. Do not exceed 1% times the hole diameter as positive effects of pipe rotation may be negated. Note that increasing density, flow rate, pipe rotation, and 6-RPM reading will all result in higher ECD. If the hole begins to fracture (and ballooning initiates), lower the 6 RPM first, then pipe rotation, and finally flow rate. If possible, keep the mud weight required for hole stability, otherwise the hole will continue to de-stabilize. Caution should be exercised on tripping out of the hole. especially when large components such as stabilizers, collars, and tools are tripped through and out of a breakout section. Carefully monitor drag while tripping out of hole, and drop down and circulate when overpull limits are Teached. Reduce pulling speed if backreaming through the enlarged hole areas. It is common to require 45 minutes to one hour to pull one stand through the problem interval.VHF FTFFEFFEFTTFFEEEEECEECSCtUssS Narrow Margin Drilling 19. Prioritize wellbore stability over lost returns when programming mud weight. The consequences of wellbore collapse are greater than the consequences of lost returns. (MJT) When planning the mud weight schedule, it is necessary to balance the need for high mud weight with the potential for lost returns. Field experience has shown wellbore stability should be given priority over lost retums. The “stable” mud weight predicted by stability modeling should be used even when there is some chance it might result in lost returns due to high ECD or when low integrity is encountered. The reason is wellbore instability is often difficult to detect because some of its symptoms are very similar to other hole problems such as poor hole cleaning, differential sticking of tool joints on connections, or drag through thick filter cakes on trips. By the time it is diagnosed, the wellbore may have collapsed so severely that the drill string is stuck. In contrast, lost retum is an acute event that is immediately recognized. In most cases, losses can be stopped by reducing the mud weight and ECD below the FCS, or by building the integrity to exceed the ECD.20. Monitor ECD management practices closely on wells with little tolerance between dynamic circulation pressures and Fracture Closure Stress (FCS). (SCZ) To maintain minimum ECDs, maintain low drilling fluids plastic viscosities (PV) and 600-RPM readings and control gel strengths (especially prevent progressive gels). For techniques to manage ECD, refer to Lost Retuns and FCS Operational Practices and Integrated Hole Quality School Manuals. Critical items are: ‘© Start pipe rotation before beginning circulation to break the mudis static gel strength ¢ Use HWDP rather than collars to maximize flow clearance «Use tapered string or ream while drilling (RWD) equipment to reduce ECD ¢ At 30 degrees or greater well angles, design mud systems to manage barite sag and implement sag monitoring procedures © — Consider auto-fill liner equipment Develop tripping speed guidelines to limit swab/surge — Minimize slug volumes ¢ — Avoid drill string components with low junk slot area * Provide hole-cleaning training to rig crews on critical high angle wells Stage in hole on trips RAHDRAAHARAAARARARARARAARAARAADAAbHRSTTCTTTTTFEEUUwUUseUuUwwwuwvs © Minimize amount of cuttings in annulus when drilling with high ROP; this may require extra circulation * Minimize plastic viscosities to keep annular pressure drop as low as reasonably possible * On narrow margin wells using NAFs, run higher oil to water ratios (i.e. 80/20 instead of 70/30) * When selecting base oils, NAFs with lower kinematic viscosities and lower compressibilities are preferred 21. Develop a detailed mitigation plan for narrow margin drilling. cz) Narrow margin drilling is often misinterpreted solely as the driling margin between pore pressure and fracture gradient. However, NPT can be significant if the margin between fracture gradient and the required mud weight for wellbore stability leaves little or no room for frictional pressure loss (equivalent circulating density). Narrow margin drilling is typically indicated when the window between mud weight for borehole stability, ECD and integrity is less than 0.5 Ib/gal (0.06 sg) Non-productive time can be significant in the case of narrow margin drilling and requires a detailed contingency plan. Contact. Drilling Technical for assistance.Narrow margin drilling strategies include: STRATEGY | PRINCIPLE CommeNTs FCS Treatment | Expose low + Noextra Entre weak zone integrity zone and | equipment needs to be exposed proactively apply necessary FCS treatment Limited success if © One-time weak zone has litle treatment in ‘or no permeability case desired integrity cen be Limited success if built losses have been with NAF (damaged permeability of fracture face) - contact Dring Technical for advice DrilkN-Stress | Formulate high | * Requires Limited or no use of Fluid ‘uid loss driling modeling solids contol fluid and treat censure suocess ‘equipment, unless entire system special shale with selected ‘© Can buildiimited | shakers are used LCM and build integrity integrity “on-the- In the absence of fy” special solids control equipment may be limited to short intervals DrillN-Stress has been suocessfully applied in WBM, but 10 application to date with NAFPFFFFFFFFFFPFFEFEEESESCsUsesss StraTecy | PRINCIPLE CommeNTs Risks Micronized | Specialy treated | * Require lead Relatively expensive weighting ultra-fine time to for one-off agent (eg, | weighting agents formulate driting | application Micromax™, | have shown to fluid and import WARP™) lower ECD, into country Inadvisable if especially in ERD ‘uncontrollable ost ais © Maximum hole circulation is size 12%in expected. (14.2-mm). Micronized agents ‘© Observed side make low rheology effects also fluids, hole cleaning Tower torque can be challenging and drag and require rigorous operational hole leaning measures Managed Various + Array of Crew training Pressure techniques methods from important for Driling utilizing a mud “Poor boy" implementation Weight below (manual) control borehole stability ‘or sophisticated Lead time for special and ‘computer-driven | equipment (rotating compensating pressure well head, dling required pressure | regulation choke manifold) with ECD and backpressure Cost associated with special equipment Managed © Eliminate severe | © Limited applicability Pressure pressure Connections fluctuations while making ‘connections by compensating pressure drop from ECD